an ISO 9001:2008 Registered Company 1964-65 Ford Falcon, Ranchero Evaporator Kit (554150) 18865 Goll St. San Antonio, TX 78266 Phone: 210-654-7171 Fax: 210-654-3113 www.vintageair.com 905140 REV B 02/02/21, PG 1 OF 27 www.vintageair.com Table of Contents Thank you for purchasing this evaporator kit from Vintage Air. When installing these components as part of a complete SureFit™ system, Vintage Air recommends working from front to back on the vehicle, installing the condenser kit, hose kit, and compressor first, followed by the wiring, evaporator, and finally the control panel. Cover.................................................................................................................................. 1 Table of Contents................................................................................................................. 2 Packing List/Parts Disclaimer.................................................................................................. 3 Information Page.................................................................................................................. 4 Wiring Notice....................................................................................................................... 5 Engine Compartment Disassembly, Condenser Assembly and Installation, Compressor and Brackets, Pulleys.................................................................................................................. 6 Passenger Compartment Disassembly..................................................................................... 7 Defrost Duct Installation, Fresh Air Cap Installation.................................................................. 8 Evaporator Bracket, Evaporator Hardline & Heater Hose Fitting Installation.................................. 9 Passenger Side Firewall Modification, Driver Side Firewall Modification.......................................10 Firewall Cover Installation....................................................................................................11 Evaporator Installation........................................................................................................ 12 Drain Hose Installation, Lubricating O-rings, A/C Hose Installation............................................ 13 Heater Hose & Heater Control Valve Installation..................................................................... 14 A/C and Heater Hose Routing............................................................................................... 15 Center Louver Installation....................................................................................................16 Driver and Passenger Side Under Dash Louver Installation....................................................... 17 Final Steps........................................................................................................................ 18 Control Panel & Duct Hose Routing........................................................................................ 19 Wiring Diagram.................................................................................................................. 20 Gen IV Wiring Connection Instruction................................................................................... 21 Operation of Controls.......................................................................................................... 22 Troubleshooting Guide........................................................................................................ 23 Troubleshooting Guide (Cont.)............................................................................................. 24 Passenger Side Evaporator Rear Bracket Template.................................................................. 25 Driver Side Evaporator Rear Bracket Template....................................................................... 26 Packing List....................................................................................................................... 27 2 905140 REV B 02/02/21, PG 2 OF 27 Packing List: www.vintageair.com Evaporator Kit (554150) No. Qty. Part No. Description 1. 1 744014 Gen IV Evaporator Sub Case, 45° 4-vent with 204 ECU 2. 1 784150 Accessory Kit ** Before beginning installation, open all packages and check contents of shipment. Please report any shortages directly to Vintage Air within 15 days. After 15 days, Vintage Air will not be responsible for missing or damaged items. 1 Gen IV Evaporator Sub Case 45° 4-vent with 204 ECU 744014 2 Accessory Kit NOTE: Images may not depict actual parts and quantities. 784150 Refer to packing list for actual parts and quantities. 3 905140 REV B 02/02/21, PG 3 OF 27 www.vintageair.com Important Notice—Please Read For Maximum System Performance, Vintage Air Recommends the Following: NOTE: Vintage Air systems are designed to operate with R134a refrigerant only. Use of any other refrigerant could damage your A/C system and/or vehicle, and possibly cause a fire, in addition to potentially voiding the warranties of the A/C system and its components. Refrigerant Capacities: Vintage Air System: 1.8 lbs. (28.8 oz.) or 816 grams of R134a, charged by weight with a quality charging station or scale. NOTE: Use of the proper type and amount of refrigerant is critical to system operation and performance. Other Systems: Consult manufacturer’s guidelines. Lubricant Capacities: New Vintage Air-Supplied Sanden Compressor: No additional oil needed (Compressor is shipped with proper oil charge). All Other Compressors: Consult manufacturer (Some compressors are shipped dry and will need oil added). Safety Switches Your Vintage Air system is equipped with a binary pressure safety switch. A binary switch disengages the compressor clutch in cases of extreme low pressure conditions (refrigerant loss) or excessively high head pressure (406 PSI) to prevent compressor damage or hose rupture. A trinary switch combines Hi/Lo pressure protection with an electric fan operation signal at 254 PSI, and should be substituted for use with electric fans. Compressor safety switches are extremely important since an A/C system relies on refrigerant to circulate lubricant. Service Info: Protect Your Investment: Prior to assembly, it is critical that the compressor, evaporator, A/C hoses and fittings, hardlines, condenser and receiver/drier remain capped. Removing caps prior to assembly will allow moisture, insects and debris into the components, possibly leading to reduced performance and/or premature failure of your A/C system. This is especially important with the receiver/drier. Additionally, when caps are removed for assembly, BE CAREFUL! Some components are shipped under pressure with dry nitrogen. Evacuate the System for 35-45 Minutes: Ensure that system components (Drier, compressor, evaporator and condenser) are at a temperature of at least 85°F. On a cool day, the components can be heated with a heat gun or by running the engine with the heater on before evacuating. Leak check and charge to specifications. Bolts Passing Through Cowl and/or Firewall: To ensure a watertight seal between the passenger compartment and the vehicle exterior, for all bolts passing through the cowl and/or firewall, Vintage Air recommends coating the threads with silicone prior to installation. Heater Hose (not included with this kit): Heater hose may be purchased from Vintage Air (Part#31800-VUD) or your local parts retailer. Routing and required length will vary based on installer preference. 4 905140 REV B 02/02/21, PG 4 OF 27 www.vintageair.com Important Wiring Notice—Please Read Some vehicles may have had some or all of their radio interference capacitors removed. There should be a capacitor found at each of the following locations: 1. On the positive terminal of the ignition coil. 2. If there is a generator, on the armature terminal of the generator. 3. If there is a generator, on the battery terminal of the voltage regulator. Most alternators have a capacitor installed internally to eliminate what is called “whining” as the engine is revved. If whining is heard in the radio, or just to be extra cautious, a radio interference capacitor can be added to the battery terminal of the alternator. It is also important that the battery lead is in good shape and that the ground leads are not compromised. There should be a heavy ground from the battery to the engine block, and additional grounds to the body and chassis. If these precautions are not observed, it is possible for voltage spikes to be present on the battery leads. These spikes come from ignition systems and charging systems, and from switching some of the vehicle’s other systems on and off. Modern computer-operated equipment can be sensitive to voltage spikes on the power leads, which can cause unexpected resets, strange behavior and/or permanent damage. Vintage Air strives to harden our products against these types of electrical noise, but there is a point where a vehicle’s electrical system can be degraded so much that nothing can help. Radio interference capacitors should be available at most auto and truck parts suppliers. They typically are cylindrical in shape, a little over an inch long and a little over a half-inch in diameter, and they have a single lead coming from one end of the cylinder with a terminal on the end of the wire, as well as a mounting clip which is screwed into a good ground on the vehicle. The specific value of the capacitance is not too significant in comparison to ignition capacitors that are